Mazda Car 2002-04

Brake Pads

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable from the cable bracket and the operating lever
     

  4.  
  5. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the caliper piston inward (turn until it stops).

    Caliper
     
    Pads
     

  6.  

To install:

  1. Install or connect the following:

    Pads
     
    Caliper. Torque the caliper mount bolts to 26-28 ft. lbs. (35-39 Nm).
     
    Parking brake cable
     

  2.  
  3. Install the wheels and bleed the brake system.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Remove or disconnect the following:

    Wheels.
     
    Parking brake cable from the cable bracket and the operating lever
     
    Upper caliper mounting bolt and pivot the caliper downward off of the pads
     
    Brake pads and spring clips from the caliper support
     

  8.  

To install:



Click image to see an enlarged view

Fig. Location of the manual adjustment gear on the rear caliper-626

  1. Turn the manual adjustment gear counterclockwise using an Allen wrench to retract the caliper until it stops.
  2.  
  3. Install or connect the following:

    Brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
     

  4.  
  5. Turn the adjustment gear clockwise until the pads start to touch the rotor and back of the gear13
  6.  
  7. Lubricate the top caliper mounting bolt, then tighten the bolt to 26-28 ft. lbs. (35-39 Nm). Attach the parking brake cable to the operating lever.
  8.  
  9. Adjust the parking brake cable, as required.
  10.  
  11. Install the wheels.
  12.  
  13. Test the brakes for proper operation.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Plug for the manual adjustment gear. Using an Allen wrench turn the gear counterclockwise to retract the caliper piston.
     
    Lower caliper mounting bolt and pivot the caliper upward off of the pads
     
    Brake pads and spring clips from the caliper support
     

  6.  

To install:

  1. Install or connect the following:

    Brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
     
    Lubricate and install the lower caliper mounting bolt. Tighten the bolt to 26-28 ft. lbs. (35-39 Nm).
     

  2.  
  3. Turn the manual adjusting gear clockwise until the piston contacts the brake disc, then turn it clockwise13
  4.  
  5. Install the wheels.
  6.  
  7. Test the brakes for proper operation.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Lock pin and rotate the caliper upwards
     
    V-springs, pads and the shims from the pads
     

  4.  

To install:

  1. Press the caliper piston back into the cylinder.
  2.  
  3. Install or connect the following:

    Pads, shims, and V-springs
     
    Caliper and torque the lock pin to 37-50 ft. lbs. (50-68 Nm)
     
    Wheels
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable
     
    Pad retaining clip
     
    Caps from the caliper bolts
     
    Caliper mounting bolts and the caliper
     
    Outer brake pad from the mount support and pull the inner pad from the caliper
     

  4.  

To install:

  1. Install the out pad to the mounting support and clean the piston area.
  2.  
  3. Using tool 49 F043 002, turn the piston clockwise slowly until the piston is fully seated in its bore.
  4.  
  5. Align the inner side pad spring with the piston groove and insert the pad. Refer to the illustration for spring location and inner pad installation arrow.
  6.  
  7. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 19-22 ft. lbs. (25-30 Nm). Install the bolt caps.
     
    Pad retaining clip and parking brake cable
     
    Wheels
     

  8.  
  9. Pump the brake pedal several times to seat the pads. Inspect the parking brake lever stroke and brake drag and adjust as necessary.
  10.  


    Click image to see an enlarged view

    Fig. Turn the rear caliper piston clockwise slowly until the piston is fully seated in its bore-Mazda 3



    Click image to see an enlarged view

    Fig. Align the inner side pad spring with the piston groove and insert the pad-Mazda 3


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable clip
     
    Upper caliper bolt and rotate the caliper downwards
     
    V-springs, pads and the shims from the pads
     

  4.  

To install:

  1. Press the rear caliper pistons back into their bores using tool 49 FA18 602.
  2.  
  3. Install or connect the following:

    Pads, shims, and springs
     
    Caliper and torque the bolt to 27-36 ft. lbs. (37-49 Nm)
     
    Wheels
     

  4.  


    Click image to see an enlarged view

    Fig. Press the rear caliper pistons back into their bores using tool 49 FA18 602-Mazda 6


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Remove the wheels.
  8.  
  9. Disconnect the parking brake cable from the cable bracket and the operating lever. Remove the screw plug. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston inward (turn until it stops).
  10.  
  11. Remove the upper caliper mounting bolt and pivot the caliper upward off of the pads.
  12.  
  13. Remove the brake pads and spring clips from the caliper support.
  14.  

To install:

  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  
  3. Install the bottom caliper mounting bolt. Tighten the bolt to 33-44 ft. lbs. (46-60 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 10 ft. lbs. (14 Nm).
  4.  
  5. Adjust the parking brake cable, as required.
  6.  
  7. Install the wheels.
  8.  
  9. Test the brakes for proper operation.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Remove the wheels.
  8.  
  9. Disconnect the parking brake cable from the cable bracket and the operating lever.
  10.  
  11. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads.
  12.  
  13. Remove the brake pads and spring clips from the caliper support.
  14.  

To install:

  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  
  3. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 26-28 ft. lbs. (35-39 Nm). Attach the parking brake cable to the operating lever.
  4.  
  5. Adjust the parking brake cable, as required.
  6.  
  7. Install the wheels.
  8.  
  9. Test the brakes for proper operation.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the plug for the manual adjustment gear. Using an Allen wrench turn the gear counterclockwise to retract the caliper piston.
  8.  
  9. Remove the lower caliper mounting bolt and pivot the caliper upward off of the pads.
  10.  
  11. Remove the brake pads and spring clips from the caliper support.
  12.  

To install:

  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  
  3. Lubricate and install the lower caliper mounting bolt. Tighten the bolt to 25-29 ft. lbs. (34-39 Nm).
  4.  
  5. Turn the manual adjusting gear clockwise until the piston contacts the brake disc, then turn it clockwise 1 / 3 turn. Replace the plug.
  6.  
  7. Install the wheels.
  8.  
  9. Test the brakes for proper operation.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the lock pin and rotate the caliper upwards.
  6.  
  7. Remove the V-springs and remove the pads. Remove the shims from the pads.
  8.  

To install:

  1. Press the caliper piston back into the cylinder.
  2.  
  3. Install the pads, shims, and V-springs.
  4.  
  5. Install the caliper and torque the lock pin to 37-50 ft. lbs. (50-68 Nm).
  6.  
  7. Install the wheels.
  8.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable clip
     
    Upper caliper bolt and rotate the caliper downwards
     
    V-springs, pads and the shims from the pads
     

  4.  

To install:

  1. Press the rear caliper pistons back into their bores using tool 49 FA18 602.
  2.  
  3. Install or connect the following:

    Pads, shims, and springs
     
    Caliper and torque the bolt to 27-36 ft. lbs. (37-49 Nm) on Mazda6models, or 16-23 ft. lbs. (21-31 Nm) on Mazdaspeed6 models
     
    Wheels

    Click image to see an enlarged view

    Fig. Press the rear caliper pistons back into their bores using tool 49 FA18 602-Mazda6

     

  4.  

626
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Remove or disconnect the following:

    Wheels.
     
    Parking brake cable from the cable bracket and the operating lever
     
    Upper caliper mounting bolt and pivot the caliper downward off of the pads
     
    Brake pads and spring clips from the caliper support

    Click image to see an enlarged view

    Fig. Location of the manual adjustment gear on the rear caliper-626

     

  8.  

To install:

  1. Turn the manual adjustment gear counterclockwise using an Allen wrench to retract the caliper until it stops.
  2.  
  3. Install or connect the following:

    Brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
     

  4.  
  5. Turn the adjustment gear clockwise until the pads start to touch the rotor and back of the gear 1 / 3 turn.


  6.  
  7. Lubricate the top caliper mounting bolt, then tighten the bolt to 26-28 ft. lbs. (35-39 Nm). Attach the parking brake cable to the operating lever.
  8.  
  9. Adjust the parking brake cable, as required.
  10.  
  11. Install the wheels.
  12.  
  13. Test the brakes for proper operation.
  14.  

Mazda 3
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable
     
    Pad retaining clip
     
    Caps from the caliper bolts
     
    Caliper mounting bolts and the caliper
     
    Outer brake pad from the mount support and pull the inner pad from the caliper
     

  4.  

To install:

  1. Install the out pad to the mounting support and clean the piston area.
  2.  
  3. Using tool 49 F043 002, turn the piston clockwise slowly until the piston is fully seated in its bore.
  4.  
  5. Align the inner side pad spring with the piston groove and insert the pad. Refer to the illustration for spring location and inner pad installation arrow.
  6.  
  7. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 19-22 ft. lbs. (25-30 Nm). Install the bolt caps.
     
    Pad retaining clip and parking brake cable
     
    Wheels
     

  8.  
  9. Pump the brake pedal several times to seat the pads. Inspect the parking brake lever stroke and brake drag and adjust as necessary.

    Click image to see an enlarged view

    Fig. Turn the rear caliper piston clockwise slowly until the piston is fully seated in its bore-Mazda 3



    Click image to see an enlarged view

    Fig. Align the inner side pad spring with the piston groove and insert the pad-Mazda 3

  10.  

Mazda 6
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable clip
     
    Upper caliper bolt and rotate the caliper downwards
     
    V-springs, pads and the shims from the pads
     

  4.  

To install:

  1. Press the rear caliper pistons back into their bores using tool 49 FA18 602.
  2.  
  3. Install or connect the following:

    Pads, shims, and springs
     
    Caliper and torque the bolt to 27-36 ft. lbs. (37-49 Nm)
     
    Wheels

    Click image to see an enlarged view

    Fig. Press the rear caliper pistons back into their bores using tool 49 FA18 602-Mazda 6

     

  4.  

Miata
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Plug for the manual adjustment gear. Using an Allen wrench turn the gear counterclockwise to retract the caliper piston.
     
    Lower caliper mounting bolt and pivot the caliper upward off of the pads
     
    Brake pads and spring clips from the caliper support
     

  6.  

To install:

  1. Install or connect the following:

    Brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
     
    Lubricate and install the lower caliper mounting bolt. Tighten the bolt to 26-28 ft. lbs. (35-39 Nm).
     

  2.  
  3. Turn the manual adjusting gear clockwise until the piston contacts the brake disc, then turn it clockwise 1 / 3 turn. Replace the plug.
  4.  
  5. Install the wheels.
  6.  
  7. Test the brakes for proper operation.
  8.  

Millenia
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Lock pin and rotate the caliper upwards
     
    V-springs, pads and the shims from the pads
     

  4.  

To install:

  1. Press the caliper piston back into the cylinder.
  2.  
  3. Install or connect the following:

    Pads, shims, and V-springs
     
    Caliper and torque the lock pin to 37-50 ft. lbs. (50-68 Nm)
     
    Wheels
     

  4.  

Protege
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Parking brake cable from the cable bracket and the operating lever
     

  4.  
  5. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the caliper piston inward (turn until it stops).

    Caliper
     
    Pads
     

  6.  

To install:

  1. Install or connect the following:

    Pads
     
    Caliper. Torque the caliper mount bolts to 26-28 ft. lbs. (35-39 Nm).
     
    Parking brake cable
     

  2.  
  3. Install the wheels and bleed the brake system.
  4.  

 
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